Outback Power Systems EXTREME OBX-IC2024S-120 User manual

OBX-IC2024S-120/60
Owner’s Manual
Installation and Operation
Rugged Water Resistant
Inverter / Charger

OutBack Power Systems
OutBack Power Systems is a leader in advanced energy conversion technology. Our products include
true sine wave inverter/chargers, maximum power point charge controllers, system communication
components, as well as breaker panels, breakers, accessories, and assembled systems.
Contact Information
Telephone: [phone] (North America) Fax: [phone]
(+34) 93.654.9568 (Barcelona, Spain)
Address: North America
19009 62nd Avenue NE
Arlington, WA USA
E-mail: [e-mail]
Web: www.OutBackPower.com
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER SYSTEMS:
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF
ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER
DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER
DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF
THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE
ENTIRELY AT THE USER’S RISK.
Warranty Summary
OutBack Power Systems Inc. warrants that the products it manufactures will be free from defects
in materials and workmanship for a period of one (1) year subject to the conditions set forth in the
warranty detail found inside the back cover of this manual.
OutBack Power Systems cannot be responsible for system failure, damages, or injury resulting from
improper installation of their products.
Notice of Copyright
User Manual, OutBack Extreme Rugged Water Resistant Inverter/Charger
©July 2009 by OutBack Power Systems. All Rights Reserved.
Trademarks
OutBack Power is a registered trademark of OutBack Power Systems.
Date and Revision
July 2009, Revision A

1
TABLE OF CONTENTS
Welcome to the OutBack Extreme Rugged Water Resistant Inverter/Charger............................................2
Parts Included........................................................................................................................................................................................3
Unit Dimensions...................................................................................................................................................................................3
Required Conductors........................................................................................................................................................................3
Environmental Concerns................................................................................................................................................................3
Inverter Maintenance........................................................................................................................................................................3
Storage .....................................................................................................................................................................................................3
Safety Instructions...............................................................................................................................................................................4
Initial Inspection...................................................................................................................................................................................4
Use and Storage...................................................................................................................................................................................4
Battery Safety Instructions........................................................................................................................................... ..................5
Mounting..................................................................................................................................................................................................6
System Protection...............................................................................................................................................................................7
Grounding Requirements......................................................................................................................................... .....................7
DC Wiring..................................................................................................................................................................................................8
Battery Wiring .......................................................................................................................................................................................9
AC Wiring ..............................................................................................................................................................................................12
MATE2 System Controller and Display................................................................................................................................15
Hot Keys............................................................................................. ....................................................................................................16
Soft Keys.................................................................................................................................................................................................19
Summary Screens.............................................................................................................................................................................19
Setup Screens.....................................................................................................................................................................................20
Summary Setup Screens........................................................................................................................... .........................21
Communication Setup Screens......................................................................................................................................23
Status Screens.....................................................................................................................................................................................25
Status Meter Screens........................................................................................................................... .................................27
Status Batt(ery) Screens.......................................................................................................................................................28
Status Error Screens...............................................................................................................................................................29
Status Warn(ing) Screens....................................................................................................................................................30
Status Disconnect Screens................................................................................................................................................31
Installation Drawing........................................................................................................................................................................32
Installation Check List....................................................................................................................................................................33
OBX-IC2024S-120/60 Inverter/Charger Specifications.......................................................................................34
OBX-IC2024S-120/60 Inverter/Charger Default Values........................................................................................37
Maintenance........................................................................................................................................................................................38
Troubleshooting.................................................................................................................................................................................38
Warranty.................................................................................................................................................................................................39
Product Registration.......................................................................................................................................................................41

2
Welcome to the OutBack Extreme Rugged Water Resistant Inverter/Charger
The OutBack Extreme Rugged Water Resistant Inverter/Charger (hereafter called the Inverter) provides
120 Vac, 60 Hz, true-sine wave power, from a 24 Vdc battery source. It is designed for rugged operational
environments in an unprotected, uncontrolled climate. This equipment is intended for use on tracked and
wheeled vehicles, and above deck and other areas where it will be exposed to unfavorable conditions.
OutBack Power Systems does everything possible to assure the components you purchase will function
properly and safely when installed as instructed according to local and national electrical codes. Please read
all of the following instructions and the instructions that come with any other OutBack components that
make up your power system. Further instructions on individual Inverter setups as well as systems assemblies
are included with the FLEXware manuals.
This Owner’s Manual covers the following information:
Safety•
Inverter parts, standard and optional•
Initial inspection of the component•
Preparing the mounting surface•
Fastening the Inverter to the mounting surface•
General electrical information•
Installing and programming the MATE2 System Controller and Display (hereafter called the MATE)•
OutBack Extreme Rugged Water Resistant Inverter/Charger
Part Number OBX-IC2024S-120/60•
2000VA/24VDC•
120VAC/60Hz•
30 amp AC transfer switch with neutral-ground bond switching•
Environmentally protected unit•
Each Inverter has a single phase output marked with this symbol:
Each Inverter puts out a sine wave waveform marked with this symbol:

3
Parts Included
Standard with the OutBack Extreme Rugged Water Resistant Inverter/Charger, Model OBX-IC2024S-120/60:
• OneOwner’sManual
• OneDCCover(DCC)
• Onered(positive)andoneblack(negative)batteryterminalcap
Additional parts, included when purchasing the complete system OBX-IC2024S-120/60-K2:
• OneOutBackMATE2SystemControllerandDisplay
• OneNATOBatteryCableConnector,unwired
• Two2/0batterycables(onepositiveandonenegative),15’
• OneMaxiconcableassemblyforwatertightACinputconnections,6’
• OneMaxiconcableassemblyforwatertightACoutputconnections,6’
• OneMiniconcableassemblyforwatertightcommunicationsconnections,6’
Additional replacement system parts:
• NATOBatteryCableAssembly,15’,partnumberOBX-CABLE500-180-NATO
NOTE: Due to the variety of installation options available, mounting hardware is not included. All fasteners must be adequate
to support the weight of the Inverter. No fewer than four fasteners, one per corner, should be used for a safe installation.
Unit Dimensions
• 8.25”x16.25”x12”(20.95cmx41.27cmx30.48cm)
• 57.5lbs(26.08kg)
Required Conductors
Installations should be performed using the cables provided with the unit.
If it should become necessary to use replacement cables, the replacements MUST meet the following
minimum specications:
Use2/0AWG(0.3648”or9.26mm),4/0AWG(0.4600”or11.7mm),orlargerapprovedcablesrated•
75°CorhigherforDCwiring.
Use#10AWG(0.1019”or2.60mm)orlargerapprovedcablesrated75°CorhigherforACwiring.•
Environmental Concerns
In the event the Inverter needs to be disposed of, its aluminum casing is easily recyclable as are any
stripped-out internal metal and plastic parts. All circuit boards and electronic components should be
disposed or recycled in accordance with local environmental laws.
Inverter Maintenance
Following exposure to salt water, rinse all exposed surfaces to prevent corrosion. Recoat the DC lugs•
and other exposed conductors with dielectric grease.
Periodically check that the battery cable lugs are tight and secure, using recommended torque settings.•
Brush o excessive dust from the Inverter as needed.•
Check that all fasteners are tight.•
If the Inverter is not operating:•
Use a meter to verify the DC battery voltage at the Inverter terminals.•
Measure and verify the AC current at the Inverter output terminals.•
Swap the MATE or cable with another, particularly if the unit works and the MATE does not.•
Call OutBack Technical Support for further assistance or repairs. Being heavily sealed,•
the Inverter is not user-serviceable.
 ContactOutBackTechnicalSupportat(360)618-4363or[email protected].
(Please see the warranty section of this manual for more service information.)

4
REA DFIR ST !
SAVE THESE INSTRUCTIONS
Read all instructions and cautionary markings on the Inverter, the batteries and all appropriate sections of
this installation and user manual as well as other component manuals before using the system.
Be cautious around electricity, electrical components, and batteries. Shocks, burns, injury, and even death
can occur if anyone comes in contact with electricity.
Install all components and wiring according to any appropriate regulations. OutBack Power Systems cannot
be responsible for system failure, damages, or injury resulting from improper installation of their products.
Install the Inverter in a well-ventilated, area out of direct sunlight, preferably indoors, for best operation.
Use only the DC and AC cables provided. Be sure all wires are in good condition.
Ensure the DC negative and chassis ground are bonded together in one place, and only one place. Ensure
the AC neutral and chassis ground are bonded together in one place, and only one place.
(Seepage7formoreinformation.)
Initial Inspection
Your Inverter is stoutly packaged for secure shipping. Please inspect the packaging and component for
damage or exposure to water prior to installation. Never power up a damaged Inverter.
Use and Storage
The Inverter is designed to be exposed to wet or inclement conditions. However, it is not intended to be
energized or used while submerged. If the operating platform is submerged, the recommended practice is
to wait ve minutes after emergence before powering up the Inverter. The unit can be used any time after
theinitial5minutes.
The MATE2 System Controller and Display is not water-resistant and is not designed to be exposed to wet or
inclement conditions. If necessary, the MATE can be removed from the system while these conditions apply,
or while not in use. The Inverter has non-volatile memory and will keep all its settings.
The recommended practice for storage is for each Inverter to be kept in a cool, dry area.
READ FIRST!
IMPORTANT SAFETY INSTRUCTIONS

5
Designthebatteryenclosuretopreventaccumulationandconcentrationofhydrogengasin“pockets”at
the top of the enclosure. Vent the battery compartment from the highest point to the outside. A sloped lid
can also be used to direct the ow of hydrogen to the vent opening.
CAUTION
To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium, gel cell or absorbed
glass mat type rechargeable batteries. Other types of batteries may burst, causing personal injury and
damage. Never charge a frozen battery.
SAFETY AND HUMAN FACTORS
Someone should be within range of your voice to come to your aid if needed.•
Keep plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.•
Wear complete eye protection. Avoid touching eyes while working near batteries. Wash your hands•
with soap and warm water when done.
If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters an•
eye,oodtheeyewithcoolrunningwateratonceforatleast15minutesandgetmedicalattention
immediately following.
Baking soda neutralizes lead acid battery electrolyte. Keep a supply on hand in the battery area.•
NEVER smoke or allow a spark or ame in vicinity of a battery or generator.•
Do not contact battery lugs or ring terminals with your skin; this increases the risk of a shock.•
Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short-circuit the•
batteries or other electrical parts and can result in re or explosion.
Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a•
battery or other electrical current. A battery can produce a short circuit current high enough to weld
a ring or the like to metal, causing severe burns.
WARNING: WORKING NEAR LEAD ACID BATTERIES CAN BE DANGEROUS. BATTERIES
GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION.
IMPORTANT BATTERY INSTRUCTIONS

6
MOUNTING
TheInverterweighs57.5lbs(26.08kg)andmustbesecuredwithappropriatefastenerstoasturdy•
mounting surface capable of supporting its weight. Depending on application, it may be easier for
two people to install the unit due to the Inverter’s weight.
If internally mounted (protected from the environment), the Inverter can be mounted in any position•
or orientation. If externally mounted (exposed to the environment), the Inverter cannot be mounted
upside-down, to ensure that water will not stand under the DC cover. (It can be mounted in any other
position or orientation.) In all cases, the Inverter will perform better in locations oering plenty of air
circulation.
When mounting the Inverter on a given surface, use appropriate fasteners to support its weight.•
OutBack cannot be responsible for damage to the Inverter if it is attached with inadequate fasteners.
Install and secure each Inverter before attaching any wiring.•
If mounted on a tracked or other non-suspension-type prole, consideration should be made to use•
shock dampening technology betwen the platform and the Inverter chassis due to the potential
vibration and other mechanical energy transfer.
12.0” (30.48 cm)
Insert fasteners at all
four corners of the
Inverter for a secure
installation.
16.25” (41.27 cm)
8.25” (20.95 cm)

7
The equipment ground on each is marked with this symbol:
Box lug for grounding the
Inverter chassis
SYSTEM PROTECTION
Electrical systems are designed to protect you, the wires, the components, and the devices served by
the system.
Each Inverter must be part of a permanently grounded electrical system (see below). Grounding•
protects people and equipment from electrical shock. Grounding must be performed according to
required codes and regulations.
Circuit breakers protect wiring by limiting the amount of current entering a system. All wired•
electrical systems require circuit breakers or fuses for protection. See following pages for sizing.
OutBack Power Systems oers both breakers and fuses for overcurrent protection. If they are provided•
by other vendors, they must be properly rated.
AC AND DC GROUNDING REQUIREMENTS
Connect only to a grounded, permanent wiring system. Use the box lug on top of the Inverter.•
For all installations, the negative battery conductor should be bonded to the grounding system at•
one (and only one) point in the system.
The Inverter should never be positive-grounded or used in a positive-ground installation. (In other•
words, never connect battery positive to ground).
For all installations, the AC neutral wire must be connected to the chassis ground at one (and only•
one) point in the system.
If the installation has no connection between neutral and ground, the Inverter has an internal switch•
which provides the bond when no other source is present. When a generator is used with the Inverter
under these conditions, the generator’s neutral and ground wires must also be bonded together, so
that its bond protects the system when the generator is running. The neutral wires on the Inverter’s
input and output plugs must be electrically isolated from each other.
If the load panel on the Inverter’s output has neutral and ground bonded together, you should•
disable the Inverter’s automatic bond switching. (Instructions for this are on page 13.) Under these
conditions, the generator’s neutral and ground should NOT be bonded together. The Inverter’s input
and output neutral wires can be electrically common.
Failing to establish a neutral-ground bond is a safety hazard. Establishing more than one bond can•
result in nuisance tripping of GFCIs, and is also a safety hazard.

8
WIRE CONNECTIONS
DC Wiring
TheInverterusesDCbrassbatteryterminalswith8Mx1.00stainlesssteelthreadedstuds.Youcanaccess
the terminals by removing the four screws that attach the DC cover plate, and pulling it o.
Red terminal=battery positive Battery terminal covers
Black terminal = battery negative
Never install extra washers or any other hardware between the terminal mounting surface and the•
battery cable lug—the connection must be direct and secure.
FortheInvertermodelOBX-IC2024S-120/60,a175-ampDCbreakerisrecommended.Ifa•
DC fuse is used, it should be a Class T fuse and must not exceed a rating of 300 amps.•
Always install breakers or fuses on the positive battery cable.•
It is recommended to twist the positive and negative conductors around each other during•
installation. This is to reduce EMI (electromagnetic interference) emissions.
Use torque values from the chart below for tightening battery connections and Inverter DC connections.•
Connection Torque
DC Battery Connections to 10 foot-lbs/13.6 Nm
Inverter’s DC terminals to5foot-lbs/5.8Nm
Battery Terminal Covers
The caps are made of sti plastic with a snap-on design; remove them carefully using a at-blade•
screwdriver inserted into the slots on the sides of each cover.
Always keep the battery terminal covers installed.•
Battery Cable Lug
Lock Washer
Flat Washer
Nut
Insulator
Stud